Motor vehicle body structure for receiving snap-fit modular headliner fasteners

ABSTRACT

A motor vehicle body support structure for receiving a snap-fit fastener from a modular headliner. The vehicle body structure includes sheet metal members defining slots having longitudinal axes extending in the left to right and front to back directions. The longitudinal axes of the slots which are in alignment extend in mutually perpendicular directions such that a modular headliner may be assembled to multiple sheet metal members while maintaining alignment of the modular headliner within the motor vehicle to which it is being installed.

DESCRIPTION

1. Cross Reference to Related Applications

This application relates to the following simultaneously filed patentapplications: U.S. application Ser. No. 204,804, for HEADLINER ANDSUNSHADE FASTENER by James D. Dowd, David M. Hilborn, Roy Weilant andAbdolhossein R. Lawassani; U.S. application Ser. No. 204,662, for ASSISTSTRAP FOR A MODULAR HEADLINER by James D. Dowd, David H. Hilborn,Matthew J. Brown and Richard P. Bozyk; U.S. application Ser. No.205,139, for MODULAR HEADLINER ASSEMBLY by James D. Dowd and DarrelHampton; U.S. application Ser. No. 205,257, for SUNSHADE WITH SNAP-FITFASTENER by James D. Dowd, David M. Hilborn, Roy Weilant, andAbdolhossein R. Lawassani; U.S. application Ser. No. 204,670, for ASSISTSTRAP FOR A MOTOR VEHICLE by James D. Dowd, David M. Hilborn, andMatthew J. Brown; U.S. application Ser. No. 205,150, for SUNSHADEFASTENER MODULE FOR USE WITH MODULAR HEADLINER by James D. Dowd, DavidM. Hilborn, Roy Weilant, and Abdolhossein R. Lawassani; U.S. applicationSer. No. 105,130, for FRONT LAMP MODULE AND SUNSHADE SUPPORTS FORMODULAR HEADLINER by James D. Dowd, David M. Hilborn, Roy Weilant, andAbdolhossein R. Lawassani; U.S. application Ser. No. 205,265, forCONSOLE MOUNTED TO A HEADLINER by David M. Hilborn and Stephen P.McGarry; U.S. application Ser. No. 205,131, for MODULAR HEADLINERINCLUDING A WIRE HARNESS by James D. Dowd, Darrel Hampton, and StephenP. McGarry.

2. Technical Field

The present invention relates to the positioning of multiple openings indistinct sheet steel members to provide for the necessary flexibility,alignment and support for a snap-fit modular headliner to be mountedwithin a motor vehicle.

BACKGROUND OF THE INVENTION

In order to provide a modular headliner which may be snap-fit into thevehicle body structure, it is necessary to provide appropriate openingsto allow the modular headliner to be installed while recognizing thatpart variances and tolerances, welding and other factors affect thevehicle part spacing and alignment during the assembly process. Thetypical structure to which the sunshades and headliner are mounted is anextending flange from the A-pillar inner (also known as windshield sideinner) on either side of the front of the car. These two A-pillar innersare completely distinct sheet steel members. The spacing betweenopenings formed one in each A-pillar is not necessarily consistent noris the front to back spacing constant. A header (also known as awindshield inner upper) extends across the front of many vehicles abovethe terminal ends of the A-pillar inners and may be formed such that allthe openings therein are stayed simultaneously such that the positioningbetween the openings therein is maintained constant. The problem is thento determine how to mount a modular headliner using a snap-fitengagement to the sheet metal of the body structure and still providefor finished vehicles having the headliner installed at the rightlocation in alignment and otherwise be a world class product.

The herein described combination of openings, having a long dimensionfor allowing sliding movement of the fastener within the opening in onedirection and having a shorter dimension for preventive sliding motionin the opposite direction has been found particularly useful with thefastener of the type shown. By providing a plurality of openings, it ispossible to maintain the desired alignment of the headliner whileallowing for a snap-fit arrangement. If a modular headliner was mountedonly to A-pillar openings, then based upon the alignment of the openingsin the A-pillar, the entire headliner might be skewed due to a minorvariation in the relative positions of the openings, such as variationswhich usually occur during the assembly process.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a sheet metalstructure for receiving a snap-fit fastener.

It is another object of the present invention to provide a plurality ofopenings appropriately arranged such that a modular headliner may beinstalled on a snap-fit basis thereto while being appropriately alignedwith the vehicle.

It is another object of the present invention to provide a sheet metalstructure defining openings to allow components to be secured thereto.

A still further object of the present invention is to provide a safe,economical, reliable and easy to utilize configuration of fasteningopenings.

Other objects will be apparent from the description to follow and fromthe appended claims.

These and other objects are achieved according to a preferred embodimentof the invention by the provision of a motor vehicle body supportstructure for receiving a snap-fit modular headliner wherein the motorvehicle has a front and a back, a left side and a right side, includinga left side A-pillar sheet metal means extending in the generallyhorizontal plane adjacent the front left side of the roof and defining aleft side A-pillar opening extending in the left to right direction, aright side A-pillar sheet metal means extending in the generallyhorizontal plane adjacent the front right side of the roof and defininga right side A-pillar opening extending in the left to right directionand a header extending adjacent the roof from the left side A-pillarsheet metal means to the right side A-pillar sheet metal means, saidheader defining a left side header opening extending in a front to reardirection and a right side header opening extending in a front to reardirection, said header opening being positioned in alignment withA-pillar openings.

Also disclosed is a motor vehicle body structure including sheet metaldefining a series of openings sized to allow snap-fit fasteners from amodular headliner to extend therethrough and to engage the sheet metaladjacent to the openings for mounting the modular headliner to thevehicle body structure which includes means for receiving a left sidesunshade fastener and including a first sheet metal means defining aslot extending in a first direction and second sheet metal meansdefining a slot extending in a second direction generally perpendicularto the first direction and means for receiving a right side sunshadefastener including a third sheet metal means defining a slot extendingin a third direction and fourth sheet metal means defining a slotextending in the fourth direction generally perpendicular to the thirddirection. The second and third sheet metal means may be a unitary sheetmetal member such as the header whereas the first and fourth sheet metalmeans may be the respective A-pillar inners. Additionally, the motorvehicle includes a left side rail inner and a right side rail inner eachof which defines openings which is appropriately sized to receive afastener extending from a modular headliner.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a modular headliner assembly positionedadjacent the vehicle windshield opening for assembly therethrough.

FIG. 1A is a partially sectioned view of FIG. 1 taken at the indicatedline.

FIG. 2 is an exploded perspective view of a modular headliner assemblyand appropriate portions of the vehicle body structure.

FIG. 3 is a partially sectional end view of a sunshade/headlinerfastener shown mounted in the vehicle.

FIG. 3A is a partial sectional view of a portion of thesunshade/headliner fastener.

FIG. 3B is a sectional view of FIG. 3A taken at the indicated line.

FIG. 3C is a sectional view of FIG. 3A taken at the indicated line.

FIG. 4 is an exploded view of a headliner/sunshade fastener and vehicleparts to which it is assembled.

FIG. 4A is a side view of a sunshade fastener.

FIG. 5 is a top view of the vehicle body structure showing the mountinglocations for a modular headliner.

DESCRIPTION OF THE PREFERRED EMBODIMENT

The invention will be described with reference to a specific embodimentor embodiments hereof. It is understood that this invention hasapplicability with minor modifications to many vehicle lines, bodystyles, trim levels and structures, and it is to be anticipated thatvarious changes can be made to the disclosed embodiments within thespirit and scope of the invention.

FIG. 1 is a perspective view of a modular headliner assembly 10 about tobe installed into motor vehicle 200. The motor vehicle is shown havingwindshield opening 20, left A-pillar 22 and right A-pillar 24. Themodular headliner is mounted into the partially assembled vehiclethrough the windshield or other large window opening which could also bethe rear window opening. In this manner, the body structure of thevehicle may be assembled prior to the modular headliner assembly beingmounted thereto.

Modular headliner assembly 10 consists of all those components betweenthe decorative interior surface of the headliner and the body structureof the vehicle. The modular headliner 10 must be appropriatelyconfigured such that when assembled, the modular headliner may beshipped, handled and installed in the vehicle and potentially mistreatedduring a portion of this process without having the interior surfacedamaged, without distortion or bending due to uneven stresses andwithout impacting the function of the various components thereof.

As may be specifically seen in FIGS. 1 and 1A, the headliner includessubstrate 12 is made from a material such as molded fiberglass, styrene,cardboard, a polymeric material, or as is otherwise known in the art.Substrate 12 has mounted on the surface thereof a decorative covering orsurface 16 which is the surface visible to an occupant of the finishedvehicle. The opposite side of substrate 12 from that on which decorativesurface 16 is mounted is the non-show surface, surface 14.

Left sunshade 40 and right sunshade 42 are mounted to the substrate bythe use of left sunshade fastener 4 and right sunshade fastener 46.

Additionally shown as part of the modular headliner are assist straps 80which are retained to the modular headliner by retainers 84 interactingwith assist strap legs 82.

Also shown as a portion of modular headliner 10 is center console 50which is shown secured within depressed portion 51 formed in thesubstrate to retainer 52. A mesh fastener 56 is shown located to extendupwardly from retainer 52.

Likewise, forward console 60 is shown mounted within depressed portion61 formed in the headliner in combination with forward retainer 62.Forward retainer 62 includes an outwardly projecting area through whichleft inboard sunshade support 64 and right inboard sunshade support 68extend. Appropriate retainers 66 and 70 are shown for securing the legsof the inboard sunshade supports to hold the inboard sunshade supportsin position.

Further shown as part of the modular headliner is wire harness 30 havinga wire bundle 32, including a vehicle electrical connector 34 and aseries of accessory connectors 72 located adjacent each accessoryrequiring electrical connections. Complementary connectors 74 extendfrom each accessory and mate with accessory connectors 72 to form acompleted wire harness. Vehicle electrical connector 34 is typicallyconnected to a mating connection extending from the vehicle bodyelectrical system in an easy to access area such as one of theA-pillars.

Additionally it may be seen that the modular headliner wire harness issecured within substrate channels 31 such that the wire is maintainedtherein. Additionally, adhesive 36 may be placed over the wire bundle tosecure the wire bundle within the channel. In this manner, the wires areprotected from inadvertent contact with roof bows or other roofstructure and the potential for damage to the wires is avoided.

As may be seen in FIG. 1, the modular headliner assembly is about to beinserted into the vehicle for assembly thereto. The left and rightsunshade fasteners, 44 and 46, extend upwardly and include legs forengaging with the metal structure of the vehicle to mount the samethereto. Likewise, assist straps 80 have upwardly extending legs 82which engage appropriate openings in the body structure to also securethe modular headliner to the vehicle. Furthermore, mesh fastener 56 mayappropriately interact with a corresponding mesh fastener to likewisesecure the headliner to the body structure. Hence, the left and rightsunshade fasteners and at least one of the two assist strap handles areused for securing the modular headliner assembly to the motor vehicle.Furthermore, the mesh fastener of retainer 52 may likewise serve such afunction. Also not to be ignored are the right inboard sunshade supportand the left inboard sunshade support which also includes legs forengaging the sheet metal structure of the vehicle.

In order to assemble the modular headliner to the vehicle, the headlineris slid through a large window opening such as a windshield and placedin general position to which it is to be mounted. An operator thenpositions one of the sunshade fasteners to feel when the fastener mateswith an appropriate opening. The sunshade fastener is then snap-fit intothe opening to mount that portion of the modular headliner. The sameprocess is then followed with the other sunshade fastener, the assiststraps and the inboard sunshade supports. In this manner, the entiremodular headliner may be snap-fit to the motor vehicle. Thereafter, anappropriate electrical connection is made at vehicle electricalconnector 34 and the assembly process for the headliner is complete.

In FIG. 2 an exploded view of a modular headliner about to be mounted toa vehicle body structure is shown. In this view it may be seen thatmodular headliner 10 incorporates many various subassemblies such thatall the appropriate subassemblies are mounted to the modular headlinerand such that may be readily fastened to the vehicle body structure.

The wire harness 30 of the modular headliner assembly includes a seriesof accessory connectors 72 adapted to be connected to the appropriateelectrical accessory mounted to the headliner. The wire harness assemblyis further shown slightly exploded from channels 31 formed in thesubstrate for securing the headliner wire harness therein. This wireharness assembly is shown somewhat schematically and may, in fact, belocated at different positions about the headliner, such positions beingchosen for having optimum room for securing wires therein and forproviding optimum space between the headliner and the vehicle bodystructure to prevent any accidental contact therebetween.

The center console 50 is shown having a complementary connector 74extending therefrom for connection to accessory connector 72. Frontconsole 60 has a complementary connector 97 and sunshade module 130 hasa complementary connector 139, designed to be connected to accessoryconnectors 72 to form the integrated wire harness of the modularheadliner assembly.

Center console 50 and forward console 60 are shown somewhat in schematicformat. It is to be understood that these consoles may include featuressuch as overhead lights, reading lights, displays, vanity mirrors,garage door opener compartments, switches, and other control featuressuch that a modular headliner wire harness may include a significantnumber of conductors. Additionally, the sunshade modules as shown areanticipated to be sunshade modules incorporating illuminated vanitymirrors which likewise require a power supply.

Center console 50 is mounted through a substrate center module opening39 formed in depressed portion of the substrate 51 to retainer 52mounted on the opposite side of the substrate. Retainer 52 may haveextending wings which act to distribute the load of the console over awide area of the substrate such that uneven loading or distortion duringthe shipping or handling process is avoided. The substrate about theconsole is depressed and defines an opening therein. The console coversthe end of the depression including the opening to form a neat, highlyattractive module.

Mesh fastener 56 attached to a back portion of the retainer oralternatively to the console is designed to interact with mesh fastener58 secured at location 59 to the roof bows of the vehicle bodystructure. This mesh retainer is preferably a Dual Lock® retainer. Bythe selection of Dual Lock material, it is possible that the headlinermay slide into position with one portion of the Dual Lock fastenersliding relative to the other. The Dual Lock fastener has the propertythat it does not grab and lock until the two fasteners are forced oneinto the other such as when the substrate is displaced upwardly lockingit into its final position. Prior to such time, the headliner and thetwo mesh portions may be slid relative to one another to allowpositioning and alignment of the headliner. This is quite different thanother mesh fasteners which grab upon contact and may not thereafter bereadily displaced.

Front console 60 is shown having snap legs 98 which extend upwardlythrough substrate front console opening 37 formed in depressed portion61 to engage retainer 62. Retainer 62 has wings 90 which define wingopenings 92. Inboard sunshade supports 66 and 68 extend with fasteninglegs 63 projecting upwardly through substrate openings 35, throughretainer openings 92 and are secured in position by retainers 94including spring legs 96 and, upon final assembly, extend through headeropenings 126 in the vehicle body structure. Each of the inboard sunshadesupports 66 and 68 includes a receptacle for secondary visor 67 and aslot for receiving primary visor 65. As is seen in reference to sunshademodule 130, the module includes a primary visor 132 and a secondaryvisor 134. The primary visor is mounted on the pivot rod 136 and thesecondary visor is mounted on the pivot rod 137. The sunshade modulefurther includes fastener 44 having a base 170, cover 150 and wires 138extending therebetween. The primary visor is mounted for pivotedmovement with pivot rod 136 and for rotation about the pivot rod 136between a stored position against the headliner and a downward positionto shield an occupant's eyes from sunlight entering through thewindshield. When the primary visor is pivoted to block the sunlightcoming through the side window, then the secondary visor may be rotateddownwardly to block sunlight entering in through the windshield.

Assist straps 80 include projecting legs 84 projecting through theheadliner substrate. Retainers 82 are shown in engagement with legs 84to secure the assist straps to the headliner. An assist strap mayinclude handle 86 and a coat hook 88, and is mounted in an appropriateposition to provide a grab handle for an occupant entering or leavingthe vehicle. Assist strap openings 106 are shown defined by inside rail104 of the vehicle body structure 100. It is to these assist strapopenings 106 that legs 82 engage to hold the assist strap andconsequently the modular headliner in position. Fastener 44 engages thevehicle body structure through left A-pillar opening 112 formed in leftA-pillar inner 108, a portion of A-pillar 22. In the same manner, rightfastener 44 is inserted through the right A-pillar opening 110 of rightA-pillar inner 106, a portion of right A-pillar 24. Both fasteners arelikewise mounted through header left sunshade fastener 124 and headerright sunshade fastener 122 openings, both being openings in header 120.

Vehicle body structure 100 as shown includes a series of roof bows 102and the header and A-pillars as previously mentioned. Additionally,vehicle body structure 100 includes side rail 104 defining openings 106to which the various assist strap legs may be engaged.

Hence, it may be seen from FIG. 2 that the entire modular headlinerassembly may be secured to the vehicle body structure with the vehiclebody structure merely providing appropriately sized and positionedopenings. No other structure need be added to the vehicle body structureto allow the modular headliner to be secured thereto. All the fastenersfor securing the modular headliner are affixed to the modular headlinersuch that the vehicle assembler need only mount the modular headliner tothe vehicle body structure and need not add any intermediate fastener orreceptacle portions to do such.

FIG. 3 shows a partially sectional view of fastener 44 secured to avehicle. As may be seen therein, the fastener is positioned below roof103 and fits in opening 124 of header 120 and through left A-pillaropening 112 of A-pillar inner 108. Additionally, substrate 12 having anon-show surface 14 and decorative surface 16 are shown.

Fastener 44 has a cover 150 and base 170 which includes projection forreceiving secondary visor 176 which defines an opening therein. Pivotrod flange 178 is shown encompassing pivot rod 136 although it might beconsidered to be a portion of the pivot rod as opposed to a portion ofthe base. Additionally, the base includes a torque fitting support 180through which the pivot rod will extend. The torque fitting will engagethe top of the torque fitting support such that the pivot rod ismaintained to the base by the torque fitting engaging the torque fittingsupport. The torque fitting support may include a torque fitting opening184 which allows the torque fitting to be inserted through the base,said torque fitting including a keyway and a wire guide area. Once thetorque fitting is inserted through the torque fitting support, thetorque fitting is then rotated to prevent its removal through the torquefitting support and is retained from rotation therein by torque fitting183 indent. The cover then secures the torque fitting in the position towhich it has been rotated.

Bezel 172 is shown extending generally parallel with substrate 12 and ofsufficient area to engage substrate 12 such that substrate 12 will bepushed upwardly by bezel 172 as the fastener is mounted. Centering arms174 and bezel ribs 175 are also shown extending upwardly from bezel 172.

Cover 150 defines a pair of flanges 152 and 154 extending outwardlytherefrom. These flanges are flexible and may be compressed to allow thecover to fit through the left A-pillar opening 112. Each flange has acurved end 156, and when inserted through the opening, the flange iscompressed and as the cover approaches the fully inserted position, theflange bows outwardly with only the downward most end being received bythe edges of the opening. The end of the flange is curved and thecombination of the bowing of the flange and the curve provides a cammingaction which, once the flange is released, will cause the flange to snapbehind A-pillar inner 108 as shown such that the flanges act to preventthe fastener from being moved downwardly. The center of cover 150 isdefined as torque fitting receiving area 158 into which the torquefitting connected to the rod will be maintained. Cover 150 furtherincludes platform portion 160 which engages the top surface of substrate12 and the opposite surface of A-pillar inner 108 from the surface thatthe flanges engage. Cover 150 additionally includes a platform rib -62extending downwardly from platform portion which acts to engage bezel172 and bezel ribs 175 such that spacing is provided therebetween, saidspacing being appropriately sized to receive substrate 12. Theengagement of platform rib 162 and bezel rib 175 act to align the coverto the fastener and prevent any applied torque from rotating the basewithout transmitting the rotation to the cover and consequently thevehicle body structure.

Referring now to FIG. 3A, there may be seen a partial sectional view ofthe fastener. Therein, cover 150 is shown with torque fitting 164contained therewithin. Torque fitting 164 is typically molded to thepivot rod. Annular indent 166 is provided on the pivot rod to engage thetorque fitting to prevent linear displacement of the torque fittingalong the pivot rod. Torque fitting 164 is maintained by cover 150 inthe desired position, and will not rotate relative thereto. The rod,however, will rotate relative the torque fitting and it is this torquerelationship that provides the resistance necessary as the sunshade ispivoted between the position covering the windshield and the positioncovering the side window. Platform 160 and rib 162 are shown extendingabove the substrate, the rib acting to space the cover from the base.

Wires 168 are shown extending from rod 136 and are those wires used tosupply power to the illuminated vanity mirror portions of the sunshade.Wires 168 exit upwardly from the pivot rod and then traverse downwardlywithin wire guide area 169. The wires then make a right angle turn andexit through wire opening area 167. The wires are then positioned at thetop of the substrate and may have a connector located at the end thereoffor connecting to the modular headliner wire harness.

Base 170 is shown having a bezel engaged to the substrate and isadditionally shown having screws 177 which may secure the base to thecover to form an integral fastener. Torque fitting support 180 is shownpositioned to have torque fitting 164 resting thereon such that as thebase is secured to the cover, the base through the torque fittingsupport will maintain the torque fitting in the desired position tosecure the sunshade thereto. Pivot rod flange 178 and pivot rod 136 arealso shown such that a decorative connection may be made between thepivot rod and the base. Pivot rod flange 178 may extend down the pivotrod and around a right angle bend therein.

FIG. 3B is a sectional view taken in FIG. 3A at the indicated locationshowing the various relationships between pivot rod 136 and the wirespassing therethrough. Torque fitting 164 is shown encircling pivot rod166 and includes key 151 extending outwardly to be engaged by the coverto prevent the torque fitting from rotating. Additionally shown are wireguide projections 165 defining a wire guide are 169 to which wires 168may be enclosed and also serving to prevent the torque fitting fromrotating.

FIG. 3C is a sectional view taken in FIG. 3A at the indicated locationshowing torque fitting opening 181 is sized to allow the rod with thetorque fitting mounted thereto to pass through the torque fittingsupport. The rod and fitting are thereafter rotated such that the wireguide projections and the keyway of the torque fitting engage the torquefitting support to secure the torque fitting to the fastener. Torquefitting indent 183 helps retain the torque fitting in the rotatedposition prior to the assembly of the cover to the base.

FIG. 4 is an exploded view of the fastener showing how the various partsgo together. Starting at the bottom, it may be seen that pivot rod 136has pivot rod flange 178 and torque fitting 164 secured thereto. Wireguide projections 165 are shown with wires 168 secured therebetween. Theorientation of the torque fitting is shown in the as assembledconfiguration and not in the orientation necessary to pass through thebase.

Base 170 is shown having projection for receiving secondary visor 176and an opening for the receipt of the secondary visor rod 137. Thetorque fitting support 180 is shown for the receipt of the torquefitting on the rod. Centering arms 174 are shown extending upwardly frombase 170. Substrate 12 is shown defining a substrate opening 33 throughwhich the fastener may pass. Cover 150 is shown having flanges 152 and154, a platform portion 160 and platform rib 162. An A-pillar inner 108defining an opening 112 and header 120 defining header opening 124 areshown both positioned below roof 103.

Upon assembly of the fastener, a number of interactions happen to helpsecure the entire assembly in the desired position. The pivot rod isfirst mounted to the base by the torque fitting including the pivot rodbeing inserted through the base and then rotate to its assembledposition. The pivot rod is thereby secured relative to the base by thefit of the torque fitting against the torque fitting support. The baseof the pivot rod is then placed against the substrate with the centeringarms extending outwardly therethrough and the base ribs extendingupwardly. Cover 150 is then secured to the substrate with platformportion 160 engaging the top of the substrate and platform ribs 162extending downwardly therethrough within the substrate opening 33 saidribs acting to form a spacer between the base and the cover such thatthe substrate is maintained within the space defined by the spacer andsaid ribs engaging the cover ribs to align the cover to the base and totransmit torque between the cover and the base. Centering arms 174 alsoincludes notches therein for engaging the A-pillar inner to additionallyprovide spacing. Furthermore, the coacting ribs extend upwardly from thebase to coact with the platform ribs to both align the fastener, centerthe fastener, and to additionally provide means for spacing the coverfrom the support.

The fastener is assembled by screws being inserted to secure the baseportion to the cover portion. Thereafter, the entire assembly may besnap-fit to the vehicle. As may be seen in FIG. 3, the unassembledposition, the cover is forced through a A-pillar opening 112 therebycompressing legs 152 and 154. In this position, the legs or flangesreadily fit through the opening. Once the legs or flanges have passedthrough the opening, they are released since they are no longer incontact of the opening, and the legs spring outwardly to engage thevehicle body structure on the opposite side of the A-pillar inner suchthat the sunshade and headliner are mounted to the A-pillar inner. Inthis manner, the entire modular assembly or simply a sunshade or asunshade/headliner combination are maintained in the desired position.The curvilinear ends of the flanges act to assure that the flanges willsnap outwardly. The incline or the generally pointed nature of the topof the fastener assures that the fastener will enter the openingcorrectly to facilitate the displacement of the fastener relative to theopening, said displacement acting to compress the flanges until theysnap outwardly.

Opening 112 is sized to allow the cover to pass therethrough and then toallow the fastener to slide in the left/right direction as viewed fromFIG. 4. However, centering arms 174 extend upwardly and engage the edgesof A-pillar inner 108 which define opening 112 and prevent the fastenerfrom sliding in the left/right direction as seen therein.

Header opening 124 defined by header 120 as can be seen in FIG. 4 islarger than the cover as inserted therein. However, in a planeperpendicular to the paper in FIG. 4, the header opening is sized tojust receive cover 150, and hence movement of the fastener is limited,in the direction in and out of the paper, by the fit of the cover withinthe header opening.

Referring now to FIG. 4A, there can be seen a slightly differentembodiment of the herein invention. In this embodiment, the fastenercover does not include a platform 160. Herein, the cover engages theA-pillar inner on one side and the base engages substrate 12 on theopposite side. This embodiment is specifically designed for subassemblyas a fastener and sunshade combination to a vehicle or further incombination to also secure an already positioned headliner to the motorvehicle. It is contemplated that this fastener would be used with asubcombination of simply a sunshade and a fastener which may be used toboth align an existing headliner and to provide support for theheadliner and the fastener. This combination does not provide for thesubstrate to be sandwiched between the cover and the base. As may beseen in FIG. 4A, the components are essentially the same as those of thefastener of FIG. 4 and use the same reference numerals to refer thereto.Cover 150 includes flanges 154 and 152 which engage the upward side ofA-pillar inner 108. Base 170 includes an outwardly extending bezel whichengages substrate 12 as the fastener is assembled. Pivot rod 136,projection receiving secondary visor 176, and opening 179 are alsoshown.

Further as may be seen in the various Figures, wires 168 exit thefastener through wire opening area 167. Hence, it may be seen incombination with FIG. 4A and FIG. 3A the various manners in which thewires transverse the fastener such that they may be connected to themodular headliner wire assembly.

As further can be seen in FIG. 4A, the entire fastener may be assembledincluding the sunshade assembled thereto, and then the fastener insertedthrough an opening in the substrate and then inserted through an openingin the sheet metal structure such that the substrate and sunshade towhich the fastener is attached are both secured to the sheet metalstructure.

Although not specifically apparent in FIGS. 3 or 4A, centering arms 174extend upwardly within A-pillar opening 112 or a similar opening,however, they are not in alignment with flanges 154 and 152. Hence,flanges 154 and 152 act independently of the centering arms to snap intoposition regardless of location of the centering arms. In this manner,the free compression and expansion of the flanges as the fastener isdisplaced through the opening are not impacted by the centering arms.

FIG. 5 is a top view of a motor vehicle body structure. Specifically,there may be seen windshield opening 20, and rear window opening 202 ofmotor vehicle 200. Left A-pillar inner 108 is shown defining leftA-pillar opening 112 having a longitudinal axis extending in a first(left to right) direction. Right A-pillar 106 is shown defining rightA-pillar opening 110 whose longitudinal axis is similarly oriented.Header 120 is shown having header openings 122 and 124 whoselongitudinal axes extend in a second direction (front to back) generallyperpendicular to the first direction) and header inboard sunshadesupport openings 126. Additionally, side rails 104 are shown havingopenings 106. Additionally, various arrows are shown to indicate theleft/right direction and the front/back directions relative to thevehicle.

When the modular headliner is assembled, fasteners 44 are displacedupwardly through various openings. A fastener will be displaced upwardlyuntil the cover first engages the A-pillar inner 108. The operator willthen through displacement of the angled end of cover 150 be able to feelwhen cover 150 enters into inner opening 112. The operator thendisplaces the modular headliner upwardly until the flanges pass throughopening 112 and snap outwardly to engage the modular headliner to thevehicle body structure.

However, since the left A-pillar inner and the right A-pillar inner aretwo entirely separately distinct pieces of sheet metal which areassembled to the vehicle and are subject to manufacturing tolerances andvariations, the relative positioning between the two is not alwaysmaintained constant. On the other hand, header 120 is a single stampingand contains a plurality of openings which are all fixed relative to oneanother. However, the header itself may not be necessarily secured tothe A-pillar inners and the rest of the vehicle body structure always inthe same position. Hence, the combination of openings overlapping oneanother, (being dimensioned such that each slot extends in itsrespective longitudinal direction, beyond the vertically adjacent slot)A-pillar opening 112 and header opening 124 and A-pillar opening 110 andheader opening 122 are shown. In this manner, each opening acts tosecure the displacement of the modular headliner in a single direction,but not the other direction whereby flexibility may be obtained in themanner in which the modular headliner is mounted. This flexibility isnecessary to compensate for the various tolerance and variances duringthe assembly of the vehicle. In this manner, a single fastener may firstbe mounted to the vehicle structure and the modular headliner thereafterbe pivoted to mate with the other openings while the entire modularheadliner is aligned relative to the vehicle. By providing these slidingarrangements, a snap-fit fastening arrangement may be utilized toassemble the entire modular headliner. If no provision for relativedisplacement were provided, the vehicle build would have to have precisetolerances on the openings, presently unattainable, or some other methodof adjusting the positioning of the modular headliner relative to thevehicle body structure would be necessary. However, with the provisionof overlapping holes for allowing for sliding fits between the fastenerand the combination of the headliner and the header of the A-pillarinner and the header, a snap-fit relationship is possible.

As may be specifically seen from FIGS. 2, 5 and 4, this variouscombination acts to allow a fastener to be inserted with the centeringarms 174 securing the fastener relative to A-pillar opening 112, suchthat the fastener may be displaced in the left to right direction asshown in FIG. 5, but not the front to back direction. However, the coveris appropriately sized such that the cover is not retained in the frontto back direction by the header opening such that relative to theheader, the assembly may be slid in the front to back direction.However, the cover is sized in the left to right direction relative tothe header opening such that the cover may not be slid in the left toright direction. Consequently, one opening for each fastener acts tomaintain the modular headliner in the desired position at that location.Consequently, variations between the A-pillar inner and the header areaccommodated without skewing the entire headliner module.

The invention has been described with reference to a particularembodiment. It is to be understood by those skilled in the art thatvariations and modifications can be made within the spirit and scope ofthe invention.

We claim:
 1. A motor vehicle body support structure for receiving asnap-fit modular headliner wherein the motor vehicle has a front andback, a roof, a left side and a right side, which comprises:left sideA-pillar sheet metal means extending in a generally horizontal planadjacent the front left side of the roof and defining a left sideA-pillar opening having a longitudinal axis extending in a firstdirection; and right side A-pillar sheet metal means extending in agenerally horizontal plane adjacent the front right side of the roof anddefining a right side A-pillar opening having a longitudinal axisextending in said first direction; and a header extending adjacent theroof from the left side A-pillar sheet metal means to the right sideA-pillar sheet metal means, said header defining a left side headeropening having a longitudinal axis extending in a second directiongenerally perpendicular to said first direction and a right side headeropening extending in said second direction, said header openings beingpositioned in alignment with the A-pillar openings.
 2. The apparatus asset forth in claim 1 wherein the longitudinal axes of the A-pillaropenings extend in a front to back direction and the longitudinal axesof the header openings extend in the left to right direction.
 3. Theapparatus as set forth in claims 1 or 2 and wherein the header furtherdefines a pair of inboard sunshade support openings, each inboardsunshade support opening being positioned a specific distance from arespective header opening.
 4. The apparatus as set forth in claims 1 or2 wherein the header is secured to both the left side A-pillar and theright side A-pillar.
 5. The apparatus as set forth in claims 1 or 2wherein the motor vehicle includes a left side rail inner and a rightside rail inner, each side rail inner extending from the vehicle roof tothe vehicle side and each including side rail inner openings sized toreceive a fastener extending from a modular headliner.
 6. The apparatusas set forth in claims 1 or 2 wherein the modular headliner furthercomprises a sunshade socket which may be mounted to extend through theA-pillar opening and the header opening and sized to engage the A-pillaropening to prevent movement of the socket in said second direction andto engage the header opening to prevent movement of the socket in saidfirst direction.
 7. A motor vehicle body structure including sheet metaldefining a series of openings sized to allow snap-fit fasteners from ashoulder headliner to extend there through and to engage the sheet metaladjacent to the openings for mounting the modular headliner to thevehicle body structure comprising:means for receiving a left sidesunshade fastener including first sheet metal means defining a firstslot extending in a first direction anD a second sheet metal meansdefining a second slot generally vertically aligned with said first slotand extending in a second direction generally perpendicular to the firstdirection; and means for receiving a right side sunshade fastenerincluding third sheet metal means defining a third slot extending in athird direction and fourth sheet metal means defining a fourth slotgenerally vertically aligned with said third slot and extending in afourth direction generally perpendicular to the third direction; saidslots being dimensioned and overlapped such that said first slot extendsbeyond said second slot in said first direction and said second slotextends beyond said first slot in said second direction while said thirdslot extends beyond said fourth slot in said third direction and saidfourth slot extends beyond said third slot in said fourth direction. 8.The apparatus as set forth in claim 7 wherein the second sheet metalmeans and the third sheet metal means are a unitary sheet metal memberand wherein said member defines at least two inboard sunshade supportopenings positioned to be engaged by inboard sunshade supports.
 9. Theapparatus as set forth in claim 7 and further comprising side railmembers extending along the side of the vehicle and defining assiststrap openings positioned to receive assist strap fasteners.
 10. Theapparatus as set forth in claim 7 wherein the first sheet metal meansand the fourth sheet metal means are A-pillar inners.